Electrical machine stator with optimized notch filling, and corresponding method for production of the stator

Patent metadata

Field	Value
Publication number	US-10505409-B2
Application number	US-201515304758-A
Country	US
Kind code	B2
Filing date	Apr 9, 2015
Priority date	Apr 17, 2014
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

Abstract

The invention relates mainly to an outer stator ( 15 ) for a rotary electric machine, comprising a body ( 16 ) provided with a yoke and teeth ( 25 ), with slots ( 28 ) being defined between pairs of teeth, as well as a winding comprising conductors having segment structures ( 38 ) inserted inside the slots ( 28 ). In the stator, the ratio between the width of a slot (L 1 ) covered with a slot insulator ( 145 ) and the width of a segment structure ( 38 ) covered with enamel (L 2 ) is between 0.9 and 2.

First claim

The invention claimed is:

1. A stator ( 15 ) of a rotary electrical machine, the stator comprising:
a body ( 16 ) provided with a yoke ( 26 ) and teeth ( 25 delimiting notches ( 28 ) in pairs; and
a winding ( 17 ) comprising conductors ( 37 ) with segment structures ( 38 ) inserted inside the notches ( 28 ) and covered with enamel,
each of the notches ( 28 ) covered with a notch insulator ( 145 ),
a ratio of a notch width (L 1 ) of one of the notches ( 28 ) covered with the notch insulator ( 145 ) to a width (L 2 ) of one of the segment structures ( 38 ) covered with the enamel is between 0.9 and 2.

2. The stator according to claim 1 , wherein, with edges of each notch ( 28 ) covered with the insulator having an insertion gap (J) relative to an end of a section of each of the segment structures ( 38 ), the notch width (L 1 ) is equal to the sum of the width (L 2 ) of the segment structure and twice the insertion gap (J), and wherein the twice the insertion gap (J) is less than 0.3 mm.

3. The stator according to claim 1 , wherein the notches ( 28 ) have parallel edges.

4. The stator according to claim 1 , wherein the notches ( 28 ) are trapezoidal, and are provided with edges, the directions of which converge towards the axis of the stator.

5. The stator according to claim 4 , wherein for each notch the following is defined:
a notch input gap equal to an insertion gap (J);
a notch base gap, twice the notch base gap being less than +0.5 mm.

6. The stator according to claim 1 , wherein the teeth ( 25 ) being without tooth roots extending from free ends thereof.

7. The stator according to claim 6 , wherein the teeth ( 25 ) comprise corners ( 31 ) situated at the free ends of the teeth ( 25 ) between tooth tips and tooth flanks thereof, and wherein each of the corners ( 31 ) has a rounded form according to an input radius (R).

8. The stator according to claim 7 , wherein the input radius (R) is between 0.15 mm and half a width of each of the teeth ( 25 ).

9. The stator according to claim 1 , additionally comprising outer indexing devices ( 32 ) provided on an outer periphery of the yoke ( 26 ).

10. The stator according to claim 1 , wherein the winding ( 17 ) comprises a plurality of phase windings (E 1 -E 6 ).

11. The stator according to claim 10 , wherein the segment structures ( 38 ) of two of the conductors ( 37 ) of a single phase winding are positioned alternately in an inner radial layer and an outer radial layer of the conductors ( 37 ) according to a circumference of the stator ( 15 ).

12. The stator according to claim 10 , wherein each phase winding (E 1 -E 6 ) is constituted by a single wire ( 44 ).

13. The stator according to claim 10 , wherein, for two adjacent notches ( 28 ) of a series of notches associated with a phase winding (E 1 -E 6 ), the winding ( 17 ) has two loop structures ( 39 ) situated on both sides of the stator ( 15 ) and connecting the segment structures ( 38 ) of one of the notches ( 28 ) adjacent to the segment structures ( 38 ) of the other of the notches ( 28 ).

14. The stator according to claim 13 , wherein the two loop structures ( 39 ) connect respectively a segment structure ( 38 ) belonging to the inner radial layer to a segment structure ( 38 ) belonging to the outer radial layer, and the segment structure ( 38 ) belonging to the outer layer to the segment structure ( 38 ) belonging to the inner layer.

15. The stator according to claim 1 , wherein the conductors ( 37 ) have a square or rectangular cross-section.

16. The stator according to claim 1 , wherein the segment structures ( 38 ) of the phase windings (E 1 -E 6 ) inserted in the notches ( 28 ) in the stator ( 15 ) are embossed.

17. The stator according to claim 1 , wherein the winding ( 17 ) comprises four, six or eight layers of the conductors ( 37 ) superimposed radially in the notches ( 28 ) in the stator ( 15 ).

18. A rotary electrical machine comprising a stator according to claim 1 .

19. The stator according to claim 2 , wherein the notches ( 28 ) have parallel edges.

20. The stator according to claim 2 , wherein the notches ( 28 ) are trapezoidal, and are provided with edges, the directions of which converge towards the axis of the stator.

Assignees

• Valeo Equip Electr Moteur

Inventors

• Darras Ludovic
• Ramet Vincent
• Kadiri Mostafa
• Even Denis
• Duquesne Jean
• Sapotille Larry

Classifications

• H02K15/085

  by laying conductors into slotted stators · CPC title

• H02K3/345 Primary

  between conductor and core, e.g. slot insulation · CPC title

• H02K1/16 Primary

  Stator cores with slots for windings · CPC title

• H02K15/10

  Applying solid insulation to windings, stators or rotors, e.g. applying insulating tapes · CPC title